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HOW TO - Repairing / Fixing / Modifying 1.9 DTH CDTI Swirl Flaps Bar

Discussion in 'All Model Vauxhall / Opel / GM / Holden How2' started by Jimmy-James, Feb 4, 2013.

  1. handymandave

    handymandave Member

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    Drives:
    2005 Vectra CDTI SRI 180bhp
    Hi Guys. I have a higher Mileage Vectra CDTI SRI . My Flaps were completely stuffed, x2 open and x2 closed, Bar loose and Car was very Smokey and low on power. Though very capable of fixing this problem myself I opted to do it the quick-cheap way. Here's a Video how I cured it for about £4, the 'pips' on top of Swirl Actuators were missing on 2 of them, so this limited my options as couldn't just fit a new Bar.. NEVER Jet wash the engine directly on these!. If you do Water probably likely Will end up in your Cylinders. This will snap a Con Rod or shatter a Piston or 4 if running. In my case it was off deliberately, & just locked the Motor and blew the starter instantly. A Tow home removing all Injectors and a 10 Yard slow snatch blew it all out. No consequences Thankfully. Here's a Video link if allowed.
     
    Last edited: Jul 23, 2015
  2. Emudave

    Emudave New Member

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    Drives:
    Saab 1.9 tid 150
    Thanks cavemaster for your post how to fit swirl bar. Found new one with brass cups followed your post fitted in half hr as mine was missing now works a treat power at bottom end. Thanks again
     
    cavwebmaster likes this.
  3. BN83

    BN83 BN83

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    Location:
    Birmingham
    Drives:
    Vauxhall Signum
    This might sound really silly, but how do you remove the power cables for the glow plugs? I can't seem to get them to pull of?
     
  4. cavwebmaster

    cavwebmaster CavWeb/VxON Forums Admin & Founder Staff / Administrator VxON Club Member VxON Approved Trader

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    Location:
    Nottingham
    Drives:
    Modified Astra H Sporthatch 150 CDTI
    [/QUOTE]
    Glad it helped Dave (y)
    No doubt by now you have figured it out but for everyone else you just grip the shaft and give it a pull (although don't pull the cable)

    Oh, and if anyone that read my guide thought it could be a little easier to understand please let me know (y)
     
  5. Cranaj

    Cranaj New Member

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    Drives:
    Vauxhall Astra 1.9 CDTi SRi
    Just had issues with a blocked EGR valve, hadn't been cleaned in 64,000 fair enough. Symptoms were no power below 2k until turbo kicked in then it took off, EGR seemed to be sticking. Also the car is quite smokey in the morning, just for a split second but doesn't seem normal to me.

    Since the car is coming up 9 years old and the EGR needed attention, how likely is it the swirl flaps do? I honestly have no idea what they even do, or where to find them or I would have checked whilst doing the EGR, which was extremely easy to do. Since doing the EGR it's running great, it's just the smoke in the morning that is bugging me. Pulls hard under boost, isn't burning any fluids so think turbo is ok (for now) so quite interested in your guide, just wondering what the symptoms of a malfunctioning swirl flap bar are to begin with. Cheers :)
     
  6. cavwebmaster

    cavwebmaster CavWeb/VxON Forums Admin & Founder Staff / Administrator VxON Club Member VxON Approved Trader

    Messages:
    28,474
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    1,181
    Location:
    Nottingham
    Drives:
    Modified Astra H Sporthatch 150 CDTI
    Its probably quite likely that the swirl flap bar will need attention judging by your symptoms. If the swirl flaps are stuck closed you will have very little power below 2000rpm - and smoke - and then it will suddenly pick up. This however is the symptoms of a clogged up EGR but you can just disconnect the cable - which will close it off -

    You may also have to clean the boost pressure sensor as although it won't cause the same symptoms of a broken swirl flap bar or EGR it will hold back the boost:

    http://www.vauxhallownersnetwork.co...l-1-9-16v-dth-cdti-turbo-boost-sensor.321005/

    If you take off the engine cover (just pull up on all 4 corners) you will see a long gap with 4 rods with cables on the top (glowplugs) and laying at the bottom you will see the swirl flap bar. If It's just laying at the side then the bushes on it have worn and its fallen off so it will need attention. Ill get a picture taken tomorrow so you know what you're looking for (y)
     
  7. Cranaj

    Cranaj New Member

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    Drives:
    Vauxhall Astra 1.9 CDTi SRi
    Thanks pal.

    I forgot to mention I did the boost sensor at the same time, took 2 minutes and was also caked in crap. The car is running spot on at the minute, EML light is still on though (227956), going to order a scan tool to clear the code. Pulls hard in all gears, MPG is excellent, no noises just that bit of smoke in the morning. When I cleaned the EGR it was quite obvious it was sticking open when I pushed the spring in manually every other time it would just stick open.
     
  8. courierman

    courierman New Member

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    astra h
    Hi guys my eml light has just come on now aswell and got a call from surreyside autohaus a few hours after dropping it off saying she needs a swirl flap rod and 1 swirl flap spindle what the rod locks onto. But then 10 mins later got another call saying cant get the spindle so hes going to just remove the swirl flaps and assured me they do it all the time in bmw's merc's and have done a few vauxhalls and not to worry, also said he will block egr and remap at the same time. Hopefully should have it back tuesday expected so il let you know how she drives and effects on the drive as i drive all day being a courier.

    Cambelts due soon so might have to take a bit pain in my.pocket
     
  9. Cranaj

    Cranaj New Member

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    Vauxhall Astra 1.9 CDTi SRi
    Did you find out what your code was before you gave it to the garage? Would you not need to take the manifold off to block the swirl flaps? Lot of labour involved for that I hear.

    I was tempted to get rid of all the eco crap but my mate did on his Golf 2.0 GT TDI and has had nothing but problems with it since. I don't mind cleaning the EGR out a couple of times per year it's a stupidly easy job really.
     
  10. courierman

    courierman New Member

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    astra h
    I didnt ask for the code or description as he is such a good guy and i totally trust his diagnosis, he works on my bmw 330d aswell and girlfriends golf tdi 170bhp which he done a dpf removal and intake manifold motor delete along with manifold flaps and the car runs brilliant with the remap to cater for everything.

    He did say he would have to remove cambelt, fuel pump and intake manifold to fix it which sounds like quite a bit of work, but i just need the astra van running right and reliable and back on the road asap, iv decided i should just get the cambelt done at the same time, always looks after me anyway, should be able to do my deliverys quicker after this remap
     

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